Apparatus and method for detecting leakage from a composition-containing pouch

ABSTRACT

An apparatus and a method for detecting leakage from a composition-containing pouch during the high-speed manufacturing process. The apparatus comprises: a platen comprising a pouch cavity and a plurality of platen edges adjacent to the cavity; an image capturing unit; an image processing unit; and ultraviolet-light emitting source. The composition itself comprises a fluorescent whitening compound. The ultra-violet emitting light source is arranged to illuminate the cavity and plurality of platen edges. The image capturing unit is arranged to capture an image of the illuminated cavity and plurality of platen edges. The image capturing unit is communicably attached to the image processing unit.

FIELD OF THE INVENTION

This disclosure relates to a machine vision method for detecting leakagefrom a composition-containing pouch during the manufacturing process andan apparatus used therefore.

BACKGROUND OF THE INVENTION

Consumer products are manufactured on high-speed production lines. Aproduction line typically includes a series of steps or stations atwhich different portions of the consumer product are made and/ormodified. These steps are often accomplished at the highest possiblespeed, so as to achieve a high output and low production costs. Yet itis still desirable to maintain the required quality standards for theconsumer product. As such, high-speed production lines typically includea means of inspecting the completed consumer product(s).

Manual or digital inspection of every single product at the end of ahigh-speed production line may be inefficient for a number of reasons.First, it is time consuming to inspect each and every consumer productthat comes off of a high-speed production line. Indeed, it oftentimes issimply impractical. One solution to this problem is to manually ordigitally inspect a sampling of the consumer product. However, use ofthis approach ultimately may mean that that some faulty consumerproducts escape the inspection process and/or faulty products are notidentified until it is too late to correct outages along the productionline. This can result in whole batches of faulty consumer products,which may not be marketable “as is.”

Consumer products made along high-speed production lines include pouchesthat are used to package household care compositions such as laundry ordish detergent. The current pouches on the market include singlecompartment pouches as well as multi-compartment pouches, which arecollectively referred to herein as “unit dose pouches.” The compartmentsare manufactured along high-speed production lines using platenscomprising a series of mold cavities into which water-soluble film isdrawn and is deformed such that it takes the cavity's shape. Theresulting compartments may then be sealed to form a single-compartmentpouch or at least a portion of a multi-compartment pouch. In this way,multiple unit dose pouches are made simultaneously. If at least one ofthose unit dose pouches is defective, the composition may leak, causingcontamination of the production line and/or other unit dose pouches.

SUMMARY OF THE INVENTION

There remains a need for an efficient, fast and thorough method andapparatus for inspecting unit dose pouches for quality assurance as theyare being made along a high-speed production line. The presentdisclosure addresses the aforementioned need by providing aconverter-integrated machine apparatus and a method for monitoring thequality of unit dose pouches.

A new apparatus for detecting leakage from a composition-containingpouch during the high-speed manufacturing process is described herein.The apparatus comprises: a platen comprising a pouch cavity and aplurality of platen edges adjacent to the cavity; an imaging unit; animage processing unit; and an actinic radiation emitting source. Theactinic radiation emitting source may be an ultra violet light. Theactinic radiation-emitting source is arranged to expose at least one ofthe plurality of platen edges with actinic radiation. The imaging unitis arranged to obtain an image of the at least one of the plurality ofplaten edges exposed to the actinic radiation. The imaging unit iscommunicably attached to the image processing unit.

A new method for detecting leakage from a composition-containing pouchis described herein. The method may be performed along a production lineone or more times. The composition-containing pouch is located in thecavity of a platen disposed in a pouch converting line. The compositioncomprises a photoactive compound that is responsive to actinicradiation. The platen has a plurality of platen edges adjacent to thecavity. The method comprises the following steps. At least one of theplurality of platen edges is exposed to the actinic radiation-emittingsource. An image of the at least one of the plurality of platen edgesexposed to actinic radiation is obtained. Actinic radiation emitted fromthe photoactive compound, if present on the at least one of theplurality of platen edges, is detected. If actinic radiation emission isdetected, a fail message is sent to a controller such as a programmableconverter (“PLC”) or programmable automation controller (“PAC”).Optionally, the controller may then direct the leaky pouch and/orpouch(es) located in an adjacent cavity or cavities to be ejected fromthe converting line.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be more readily understood with reference tothe appended drawing figures where:

FIG. 1 is a plan view of a section of a plurality of molds located on aplaten;

FIG. 2 is a plan view of a section of a plurality of molds located on acircular drum;

FIG. 3 is a three compartment unit dose pouch;

FIG. 4 is a block diagram of an exemplary vision apparatus;

FIG. 5 is a picture of a row of pouches that have passed inspection;

FIG. 6 is a picture of a row of pouches that have failed inspection.

The patent or application file contains at least one drawing executed incolor. Copies of this patent or patent application publication withcolor drawings will be provided by the office upon request and paymentof the necessary fee.

DETAILED DESCRIPTION OF THE INVENTION

“Comprising” as used herein means that various components, ingredientsor steps can that be conjointly employed in practicing the presentdisclosure. Accordingly, the term “comprising” encompasses the morerestrictive terms “consisting essentially of” and “consisting of”. Thepresent compositions can comprise, consist essentially of, or consist ofany of the required and optional elements disclosed herein.

Manufacturing Process

Unit dose pouches are made using suitable equipment and methods. Forexample, unit dose pouches are made using vertical form filling,horizontal form filling, and/or rotary drum filling techniques commonlyknown in the art. Such processes may be either continuous orintermittent. Examples of continuous in-line processes of manufacturingwater-soluble containers are set forth in U.S. Pat. No. 7,125,828, U.S.2009/0199877A1, EP 2380965, EP 2380966, U.S. Pat. No. 7,127,874 andUS2007/0241022 (all to Procter & Gamble Company, Ohio, USA). Examples ofnon-continuous in-line processes of manufacturing water-solublecontainers are set forth in U.S. Pat. No. 7,797,912 (to ReckittBenckiser, Berkshire, GB). Each of these processes may utilize a platencomprising a plurality of mold cavities.

Generally, the process may comprise the following steps. A film isheated and/or wetted and fed onto the surface of the platen. Once on thesurface of the platen, the film can be held in position by any means.For example, the film can be held in position through the application ofvacuum on the film, thus pulling the film in a fixed position on thesurface. The vacuum may be applied along the edges of the film and/or onthe surface area between the mold cavities. The platen surface may haveat least some holes connected to a unit which can provide a vacuum as isknown in the art.

Any film that is suitable for making a unit dose pouch is used.Non-limiting examples of water-soluble films that are used include thosecomprising polyvinyl alcohol as described in: U.S. 2011/0204087A1 andU.S. 2011/0188784A1 (each to Procter & Gamble Company, Ohio, USA).Further non-limiting examples include commercially available filmsincluding: M8630 and M8900 supplied by MonoSol (Gary, Ind., USA) and/orfilms known under trade reference Solublon® of films supplied by Aicello(North Vancouver, BC, Canada) or Poval film supplied by Kuraray(Houston, Tex., USA).

Once open pockets of film are formed into the mold cavities, they may befilled with composition and sealed by any known method, including thosedescribed in the patent publications listed above. The sealing steptypically is accomplished by sealing a second water-soluble film to theopen top of the pocket. In some embodiments, the second water-solublefilm may itself form a portion of one or more composition containingpockets. Non-limiting filling and sealing means are described in U.S.Pat. No. 6,995,126, U.S. Pat. No. 7,125,828, U.S. 2009/0199877A1, EP2380965, EP 2380966, U.S. Pat. No. 7,127,874 and US2007/0241022 (all toProcter & Gamble Company, Ohio, USA).

Composition

The unit dose pouches may contain any composition that is suitable foran intended us. Non-limiting examples of useful compositions includelight duty and heavy duty liquid detergent compositions, hard surfacecleaning compositions, detergent gels commonly used for laundry, andbleach and laundry additives, shampoos, body washes, and other personalcare compositions. The compositions may take the form of a liquid, gel,solid or a powder. Liquid and gel compositions may comprise a solid.Solids may include powder or agglomerates, such as micro-capsules,beads, noodles or one or more pearlized balls or mixtures thereof.

Compositions useful in the present disclosure comprise a photosensitivecompound. When exposed to an actinic radiation source, thephotosensitive compound emits actinic radiation. Photosensitivecompounds of use in the present invention include fluorescent dyes,ultraviolet dyes, near infrared dyes and infrared dyes, such as thosethat are used as optical brighteners, i.e., compounds that tint laundryarticles. Optical brighteners which may be useful in the presentinvention can be classified into subgroups, which include, but are notnecessarily limited to, derivatives of stilbene, pyrazoline, coumarin,carboxylic acid, methinecyanines, dibenzothiophene-5,5-dioxide, azoles,5- and 6-membered-ring heterocycles, and other miscellaneous compounds.Examples of such brighteners are disclosed in “The Production andApplication of Fluorescent Brightening Agents”, M. Zahradnik, Publishedby John Wiley & Sons, New York (1982). Non-limiting examples of opticalbrighteners which are useful in the present compositions are thoseidentified in U.S. Pat. No. 4,790,856 and U.S. Pat. No. 3,646,015.

Non-limiting examples of stillbene derivatives of use include thefollowing. Colour Index (“C.I.”) fluorescent brightener 260 inpredominantly the alpha-crystalline form and having the followingstructure:

“Predominantly in alpha-crystalline form,” means that typically at least50 wt %, at least 75 wt %, at least 90 wt %, at least 99 wt %, or evensubstantially all, of the C.I. fluorescent brightener 260 is inalpha-crystalline form. This brightener is typically in micronizedparticulate form, having a weight average primary particle size of from3 to 30 micrometers, from 3 micrometers to 20 micrometers, or from 3 to10 micrometers. The composition may comprise C.I. fluorescent brightener260 in beta-crystalline form, and the weight ratio of: (i) C.I.fluorescent brightener 260 in alpha-crystalline form, to (ii) C.I.fluorescent brightener 260 in beta-crystalline form may be at least 0.1,or at least 0.6. BE680847 relates to a process for making C.Ifluorescent brightener 260 in alpha-crystalline form.

A further stilbene derivative of use has the structure below:

Suitable fluorescent brightener levels include lower levels of fromabout 0.01, from about 0.05, from about 0.1 or even from about 0.2 wt %to upper levels of 0.5 or even 0.75 wt %.

Further stilbene derivatives of use include2,2′-(1,2-ethenediyl)bis[5-[[4,6-bis(phenylamino)-1,3,5-triazin-2-yl]amino]benzenesulfonicacid, and 4,4′-BIS(2-DISULFONIC ACID STYRYL) BIPHENYL, which is alsoknown as C.I. Fluorescent Brightener 351. One of skill in the art maydetermine the minimum and maximum amount of actinic radiation emittingcompound to use based upon the desired level of actinic radiationemission. Often this consideration is balanced against the cost and/orusefulness of the compound in the composition as well as the sensitivityof the image unit utilized to detect the actinic radiation emittingcompound.

In one example, useful concentrations of fluorescent whitening compoundare from about 50 parts per million (“ppm”) to about 2500 ppm, fromabout 100 ppm to about 2000 ppm, and from about 200 ppm to about 1500ppm.

Platen

Typical unit dose manufacturing lines utilize a surface containing themold cavity for each compartment that forms the unit dose pouch. Often,the surface is removably connected to a moving, rotating belt, forexample a conveyer belt or platen conveyer belt. The movement of thebelt may be continuous or intermittent. The surface can be removed asneeded and replaced with another surface having other dimensions orcomprising moulds of a different shape or dimension. This allows theequipment to be cleaned easily and to be used for the production ofdifferent types of unit dose pouches. Any useful surface may be used.

Referring now to FIG. 1, one embodiment of a platen 10 of use is shown.In FIG. 1, a plurality of mold cavities 100 are present in a 2-D arrayon the surface of the platen 10. In this embodiment there are 12 moldcavities in the machine direction of the platen and 7 mold cavities inthe cross-machine direction. Each cavity may be defined by a Row, “R,”in the machine direction and a Lane, “L,” in the cross machinedirection. It follows that since there is a plurality of mold cavitieson the surface of the platen that each cavity has at least threeneighboring cavities except for those mold cavities directly adjacent tothe four edges of the platen itself 120. For example cavity 101 in FIG.1 has four neighboring cavities, 102, 103, 104 and 105, whereas cavity105, which is on the edge of the platen itself 120, has only threeneighboring cavities 101, 106 and 107. Between the cavity 101 and eachof its four neighboring cavities are platen edges 12 adjacent to thecavity.

FIG. 2 depicts another useful embodiment of a platen 10. The moldcavities 100 are located on the curved surface of a drum 11. Like theplaten described above, there are a plurality of mold cavities on thesurface of the drum, such that each cavity has at least two neighboringcavities.

Unit Dose Pouches

Single or multi-compartment pouches may be made utilizing the moldcavities such as those described above. Non-limiting examples of singlecompartment pouches and methods of making them are those that arepresently on the market under the names Tide Pods, All Mighty Pacs,Purex Ultra Packs, Persil, OMO Pods, Tesco Capsules, Arm & HammerCrystal Power Pacs. Non-limiting examples of multi-compartment pouchesand methods of making unit dose pouches are described in U.S.2010/0192986A1, U.S. Pat. No. 6,995,126, U.S. Pat. No. 7,125,828, U.S.Pat. No. 7,127,874, U.S. Pat. No. 7,964,549, U.S. 2009/0199877A1, U.S.Pat. No. 6,881,713, U.S. Pat. No. 7,013,623, U.S. Pat. No. 7,528,099,and U.S. Pat. No. 6,727,215 (each to the Procter & Gamble Company, Ohio,USA). Tide Pods and Ariel Pods are examples of multi-compartment pouchesthat are currently on the market.

Actinic Radiation-Emitting Source

Any suitable actinic radiation emitting source may be utilized to causethe photoactive compound(s) in the composition to emit actinicradiation. Non-limiting examples of suitable actinic radiation emittingsources include: an ultraviolet light; a white light; a near infra redlight; an infra red light; and combinations thereof.

Imaging Unit

The inspection of the unit dose pouch and/or the at least one of theplaten edges adjacent to the cavity in which the unit dose pouch islocated can be accomplished using any suitable camera or other opticalpicture-capturing device. Non-limiting examples of cameras of useinclude a line scan camera such as the In-Sight 5604 Camera from Cognex(Natick, Mass., USA), one of the PC line of cameras from Teledyne Dalsa(Billerica, Mass., USA), the Elixa UC8 or one of the Aviiva line ofcameras from e2v (Tarrytown, N.Y., USA), or the spL8192-39k orspL4096-70 k from Basler AG (Ahrensburg, Germany).

Image Processing Unit

The image processing unit may be a stand-alone unit or it may be anintegral part of the camera. One non-limiting example of an integratedcamera and image processing unit is the In-Sight 5604 Camera from Cognex(Natick, Mass., USA). The image processing unit inspects the imagecaptured by the camera to look for actinic radiation being emitted fromat least one of the platen edges surrounding the composition-containingpouch. If actinic radiation is detected on a platen edge, then the imageprocessing unit sends a fail message to the controller.

In one embodiment, the image processing unit integrates the capturedimage and executes a programmed process to analyze the image. Based uponthe results of the image analysis, a pass or fail decision iscommunicated to the controller.

Controller

A programmable controller is utilized. A suitable controller is selectedfrom a programmable automation controller or a programmable logiccontroller. A useful programmable automation controller may be selectedfrom the Control Logic family of programmable automatic controllers fromRockwell Automation (Anaheim, Calif., USA).

EXAMPLES

A unit dose pouch 2000 comprising three compartments as shown in FIG. 3is present in a cavity of a platen after being sealed. The compartmentseach contain 50 parts per million of C.I. Fluorescent Brightener 351. Avision apparatus according to the present disclosure is mounted in-linewith the unit dose pouch production line after the stage at which thethree compartments are sealed to each other.

FIG. 4 shows a block diagram of a vision apparatus 1000 according to thepresent disclosure. A series of Cognex In-Sight 5604 line scan visioncameras 1100 are positioned above the platen 10 and span the platen inthe cross machine direction. The camera utilizes a CCD chip (imager),which consists of a single row of pixels. The single row of pixels iscaptured repeatedly in real time synchronized with the motion of thespeed of the converter. In this way, an image of each cavity in theplaten and the edges adjacent to the cavity is captured. The camerasoftware assembles the individual rows of pixels into a single areaimage.

An ultraviolet light-emitting diode line light (“UV light”) 120 ismounted and directed at the pouch platen 10 to line up with the camerafocal center lines for lighting the cavities to be inspected by thecameras. When the converter motion begins, the UV light 120 is poweredon by the programmable automation controller (“PAC”) 1200. When poweredon, the UV light 120 emits actinic radiation that excites the C.I.Fluorescent Brightener 351 located in the pouch and, if present, on theplaten edges surrounding the pouch. The cameras are triggeredsimultaneously by an output from the line's PAC that communicates withthe cameras via an Ethernet switch. After an image of the pouches andplaten edges surrounding the pouches is captured and integrated into asingle bitmap, the cameras execute the programmed process to analyze theimage. At the same time that this image is analyzed, another triggerinput from the PAC signals the cameras to begin capturing data for thenext-in-line pouches and the platen edges surrounding those pouches.

A pass/fail decision is evaluated for each pouch location on theconverter platen. The pass/fail decision is communicated to the PAC viaan Ethernet switch. Each row and lane is determined to pass or fail ifit contains a leaker.

FIG. 5 shows an image captured by one of the four cameras. In thisembodiment, the camera is precisely aligned across the platen in thecross machine direction to line up with three pouches 2000 located inthe pouch cavities and platen edges 12 adjacent to the cavities; thecavities themselves are not visible in FIG. 5 due to the presence of thepouches 2000 in the cavities. In this embodiment, the camera hasreference regions shown as the light blue box 200 in alignment with thesides of the actual outer boundaries of the platen edges 12 surroundingeach cavity.

In FIG. 5, no actinic radiation is detected on any of the platen edges12, thus no leak is detected. The camera communicates a “pass” statusfor this row of pouches over an Ethernet IP protocol to the PAC.

FIG. 6 shows a row of pouches 2000 and associated platen edges 12.Actinic radiation 150 is detected on the platen edge 12 to the right ofthe pouch 2000 on the far right. Thus a leak is detected on the rightplaten edge 12 of this pouch. The camera communicates a “fail” status ofthis row over the Ethernet IP protocol to the PAC. The PAC then directsthat leaky pouch and its neighbor to be ejected from the convertingline.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A converter-integrated machine vision method fordetecting leakage from a composition-containing pouch, wherein: a) thepouch is located in the cavity of a platen, the platen being disposed ina pouch converting line; b) the composition comprises a photosensitivecompound responsive to actinic radiation; and c) the platen has aplurality of platen edges adjacent to the cavity; the method comprisingthe steps of: i. exposing at least one of the plurality of platen edgesto an actinic radiation-emitting source; ii. obtaining an image of theat least one of the plurality of platen edges exposed to the actinicradiation-emitting source; iii. detecting actinic radiation emission ifpresent on the at least one of the plurality of platen edges; and iv.sending a fail message to a controller if the actinic radiation emissionis detected.
 2. The method according to claim 1, wherein thephotosensitive compound is selected from the group consisting of:fluorescent dyes, ultraviolet dyes, near infrared dyes, infrared dyesand combinations thereof.
 3. The method according to claim 1, whereinthe actinic radiation-emitting source is selected from the groupconsisting of: an ultraviolet light; a white light; a near infra redlight; an infra red light; and combinations thereof.
 4. The methodaccording to claim 1, wherein the photosensitive compound is selectedfrom the group of: C.I. Fluorescent Brightener 260, C.I. FluorescentBrightener 351,2,2′-(1,2-ethenediyl)bis[5-[[4,6-bis(phenylamino)-1,3,5-triazin-2-yl]amino]benzenesulfonicacid, the compound having the following structure:

and mixtures thereof.
 5. The method according to claim 4, wherein thephotosensitive compound is present in the composition at from about 50parts per million (“ppm”) to about 2500 ppm.
 6. The method of claim 5,wherein the photosensitive compound is present in the composition atfrom about 100 ppm to about 2000 ppm.
 7. The method of claim 1, whereinthe controller is selected from the group consisting of: a programmablelogic controller and a programmable automation controller.
 8. The methodof claim 7, wherein the controller is a programmable automationcontroller.
 9. The method of claim 1, wherein the composition isselected from the group consisting of: light duty liquid detergentcompositions, heavy duty liquid detergent compositions, granulardetergent compositions, hard surface cleaning compositions, detergentgels, bleach and laundry additives, shampoos, body washes andcombinations thereof.
 10. An apparatus for detecting leakage from acomposition-containing pouch wherein the composition comprises aphotosensitive compound responsive to actinic radiation, and theapparatus comprises: a) a platen comprising a pouch cavity and aplurality of platen edges adjacent to the cavity; b) an imaging unit forobtaining an image of at least one of the plurality of platen edges; c)an image processing unit for processing an image obtained by the imagingunit; and d) an actinic radiation-emitting source; wherein: i. theactinic radiation-emitting source is arranged to expose the at least oneof the plurality of platen edges with actinic radiation; ii. the imagingunit is arranged to obtain an image of the at least one of a pluralityof platen edges exposed to actinic radiation; and iii. the imaging unitis communicably attached to an image processing unit.
 11. The apparatusof claim 10, wherein the imaging unit is a line scan camera.
 12. Theapparatus of claim 10, wherein the actinic radiation-emitting source isselected from the group consisting of an ultraviolet light; a whitelight; a near infra red light; an infra red light; and combinationsthereof.
 13. The apparatus of claim 10, further comprising a controllercommunicably attached to the image processing unit.
 14. The apparatus ofclaim 13, wherein the controller is communicably attached to the imageprocessing unit via an Ethernet IP protocol.
 15. The apparatus of claim10, wherein the controller is selected from the group consisting of: aprogrammable logic controller and a programmable automation controller.16. The apparatus of claim 15, wherein the controller is a programmableautomation controller.
 17. The apparatus of claim 11, wherein the cameracomprises the imaging unit and the image processing unit.
 18. Theapparatus of claim 10, wherein the photosensitive compound is selectedfrom the group consisting of: an ultraviolet light; a white light; anear infra red light; an infra red light; and combinations thereof. 19.The apparatus of claim 10, wherein the photosensitive compound is Themethod according to claim 1, wherein the photosensitive compound isselected from the group of: C.I. Fluorescent Brightener 260, C.I.Fluorescent Brightener 351,2,2′-(1,2-ethenediyl)bis[5-[[4,6-bis(phenylamino)-1,3,5-triazin-2-yl]amino]benzenesulfonicacid, a compound having the following structure:

and mixtures thereof.
 20. An apparatus for detecting leakage from acomposition-containing pouch wherein the composition comprisesbrightener which is responsive to ultraviolet light and the apparatuscomprises: e) a platen comprising a pouch cavity and a plurality ofplaten edges adjacent to the cavity; f) an in-line camera for obtainingand processing an image of at least one of the plurality of platenedges; g) an ultraviolet light-emitting source; and h) a programmableautomation controller communicably attached to the in-line camera via anEthernet IP protocol; wherein: iv. the ultraviolet light-emitting sourceis arranged to expose the at least one of the plurality of platen edgeswith ultraviolet light; v. the in line camera is arranged to obtain animage of the at least one of a plurality of platen edges exposed toultraviolet light; and vi. the in line camera sends a pass or failmessage to the programmable automation controller.